DONE! I used the gas torch a bit more. Before, I only heated for 1min max as I feared the case would distort if I heat it up only locally. Now I tried to spread the heat more, but insisted around the studs area. Less than 5 minutes were enough and the case was not that hot, I could almost keep my hand on it.

Now I have to read what oil galley plugs I have to take out and what tap and threaded plug I have to use for each hole. If you have suggestions, please recommend, I am sure there were several topics on this subject.
I found on aircooled.net a "kit" containing the threaded plugs for type4: (1) 1/8 NPT, (5) 1/4 NPT, and (5) 3/8 NPT.
And I have to get the case in the dishwasher to clean it. Is there anything else to put inside apart from the dishwasher tablets? Vinegar? Something else?

The stuff in dishwasher packets is pretty corrosive, I yank it and do a scrub/rinse in the bathtub with hottest water I can stand as soon as it starts dry cycle, then take it outside and blow dry with the blow gun.
If you leave it in with puddles for long it can at least discolor the aluminum.

Don't bother doing the cleaning until the oil passage plugs are out, and holes tapped and tested for correct depth.

I, for one, regularly embrace our new robot overlords, as I am the guy fixing the robots...

I'll start taking pictures. I am usually lazy about this aspect but it's important also to me to keep track of what I'm doing.
Clatter, I was just thinking I read some time ago a good topic of step-by-step rebuild, and just by a quick search on galley plugging your topic came on view. Very good info in there! I started to re-read it all.
Pile, thanks for the tip. I'll do as you recommend. I wanted to give it a bath before tapping for plugs, to work on a clean case. After tapping, of course, another bath to remove all traces of metal fragments. If i'm thinking well, it's better to give the second bath after I get the case back from line boring (it needs to be bored to the first rebuild dimension, +0.50).
I hope during the weekend I can find the brass plugs and taps and start pulling the plugs.

I was thinking use the 1.7 case because I already have it cleaned and threaded plugs and using the 2.0 crank rods and PC's with any freshening up they might need. The 2.0 is out of a bus and the engine is not seized but it won't do a complete 360, something in the heads is preventing that. Probably use the 1.7 heads as well.

I think there is more to it though. I bought this core and when I got it one valve cover and the intake manifold/injectors on that side were already removed. The guy had it in his shed for years we had to dig it out. Only cost me $50 so no biggie there.

All right, some pictures and questions. First, this is what I'm starting with.

IMG_5539.JPG

IMG_5540.JPG

Now about tapping and plugging. I did not start to pull the plugs yet, I want to be sure I take out what is needed. The kits contain 11 plugs, 1x 1/8, 5x 1/4 and 5x 3/8. I'm counting twelve plugs, one being a larger one in the oil suction galley, but I think this one shall not be replaced. It is marked brown in pictures. In my pictures I marked in blue what I consider to be 1/8, green for 1/4 and red for 3/8. So:
1. 3/8

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2. 1/4 or 1/8?
3. 1/2? not to be replaced?

IMG_5543.JPG

4,5. 3/8

IMG_5544.JPG

6. 1/4 or 3/8? seems like 1/4 would be ok.

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7,8. 1/4

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9. 1/4 Is this even a plug?

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10,11. 3/4, 12. 1/8 or 1/4?

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7 & 8 are a bit troublesome, as 1/8" is a touch too small and 1/4" is too large.
1/8" needs to be deep set.

If you have a plug for #3, pull it--- or better, _gently_ tap it out from the inside after pulling the oil pickup.
Its only under suction, you will probably be able to tap it back in with a touch of thread sealant or such.
Makes cleaning the pickup passage possible.

I, for one, regularly embrace our new robot overlords, as I am the guy fixing the robots...

#1, I would rather tap and plug. There is no brass guide for the fule pump rod (or I do not see it), but I kept the rod.
#12, good to know
#7&8, I will pull the plugs and measure the hole to see what tap to use.
#3, I would not pull if not absolutely necessary. I can clean the passage easily from both directions.

Are you wanting perfection of cleanliness,
Or insurance against plugs falling out?

1, 4 & 5 are known to fall out,
As are 10 and 11.

The rest come out just to get things clean.

If you have good tanking equipment,
Spend a bunch of time with rifle brushes and whatnot,
Didn't blast the case,
Didn't fill the case full of debris from a failure,
Etc.,
You can likely get things cleaned up nice without removing the other plugs,
However,
It _is_ best to get things as clean as you can.

Most only do those first five..
Your call.

"Oh, You don't need to do all that... The valve seats are just going to fall out of it anyway!"
- Doug Ellsworth